Metal stud system for supporting nonload bearing construction materials



Sept. 6, 1966 GILBERT 3,270,472

METAL S SYS FOR SUPPORTING NON-LOAD BE NG CONSTRUGTIO MATERIALS Filed Nov. 8, 62

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FIG. 3

5AM G LbERT INVENTOR BYWM f1 ATTGEUEYS United States Patent METAL STUD SYSTEM FOR SUPPORTING NON- LOAD BEARING CONSTRUCTION MATERIALS Sam Gilbert, Los Angeles, Calif., assignor, by mesne assignments to Kaiser Gypsum Company, Inc, Oakland, Califi, a corporation of Washington Filed Nov. 8, 1962, Ser. No. 236,343 2 Claims. (Cl. 52-348) This invention relates generally to construction materials and more particularly to a system for supporting non-load bearing walls which system includes metallic members for use in quickly and easily installing such walls or partitions and ceilings in various structures.

In the construction of commercial type buildings, particularly multi-story or high-rise type buildings, it is required to divide the floor space area into useable office space by separation thereof with non-load bearing walls. Such walls are generally constructed of dry wall board or gyp-board as distinguished from plaster. In constructing such walls the dry wall board is aflixed to studs which are held in place at the desired position between the floor and the ceiling. The studs in such construction may be formed of wood or metal. This invention is directed particularly to studs which are formed of metal.

Prior art metal studs for supporting non-load bearing dry walls have been constructed of U-shaped sheet metal having a roughened surface. The dry wall board is affixed with drill point screws to the opposed arm-s of the U-shaped sheet metal. In utilizing the drill point screws it is required that they cut first into and then through the sheet metal material, thus forming their own opening to hold the dry wall board in place. Experience has indicated that once the screw has pierced the sheet metal and is therefore started, such construction operates satisfactorily. However, in starting the drill point screw experience has indicated that the screw point travels over the surface of the U-shaped sheet metal stud even though the surface is roughened. This travel of the screw point over the surface of the stud has two disadvantages. The dry wall board is damaged as a result of the travel and sometimes to the extent that a panel of the dry wall board cannot be used and must be discarded. In addition thereto the difiiculty of starting the screw increases the time required to install such partitions or separations and as well makes it exceedingly difficult to install ceilings and the upper portions of walls where workmen must work with material that is inconveniently located and difiicult to reach. This therefore increases the cost of installing such walls. The extreme travel of the point of the screw results from a flexure of the U-shaped sheet metal stud, particularly when force is applied by the workmen to the drill point screw in an attempt to pierce the sheet metal stud.

In addition to the foregoing the prior art sheet metal studs are normally installed upon the floor or ceiling of a building by the utilization of a U-shaped channel member within which the stud is placed. The stud is then secured by such techniques as spotwelding, riveting, upsetting or screws are inserted to afiix the stud to the channel. Such procedures are again quite costly and time-consuming, thus increasing cost of installation.

Accordingly it is an object of the present invention to provide a metal stud system which is simply and easily installed and which will readily support partitions, walls and ceilings.

It is another object of the present invention to provide a metal stud system which permits rapid attachment of wall materials thereto while eliminating damage to the wall material and which will simultaneously decrease the cost of material and labor as compared to prior art structures.

3,279,472 Fatented Sept. 6, 1966 ice Additional objects and advantages of the present invention will become apparent from a consideration of the following description taken in conjunction with the accompanying drawing which is presented by way of example only and is not intended as a limitation upon the scope of the present invention as defined in the appended claims and in which:

FIG. 1 is a perspective view partly in cross section of a wall constructed in accordance with the metal stud system of the present invention;

FIG. 2 is a cross section illustrating the metal stud system in accordance with the present invention and taken about the lines 22 of FIG. 1; and

FIG. 3 is a greatly enlarged fragmentary view illustrating a particular feature of the metal stud system in accordance with the present invention.

A metal stud system in accordance with the present invention includes a mounting channel member for receiving metallic studs and which has a base member having a pair of opposed upstanding walls. Along one of the walls there is provided a plurality of partially cut-out members which may be bent inwardly over the base member to retain a stud in place within the mounting channel so that a wall material may be afiixed thereto. The stud which is held in place Within the mounting channel is a hollow elongated metallic member having at least one substantially fiat surface defining foramina in at least a portion thereof thereby to form a plurality of capture areas or trapping centers for the point of a screw. The screw is utilized to affix a wall material to the studs.

Referring now to the drawing and more particularly to FIG. 1 there is illustrated a wall which is constructed by utilizing the metal stud system in accordance with the present invention. As is therein shown 9 represents a floor and 10 a ceiling within a particular building. Held in place between the floor 9 and the ceiling 10 are a pair of metal studs 11 and 12. Additional studs similar to studs 11 and 12 are also held in place along the wall. However, for purposes of clarity of description, only the studs 11 and 12 are illustrated and described below.

The studs are held in place by a channel supporting member generally designated 13 and which includes a first base member 14. A pair of upstanding walls 15 and 16 are afiixed to the base member 14. Also included is a second base member 17 having a pair of upstanding opposed walls 18 and 19. A web 21 interconnects the upstanding wall 15 and the upstanding wall 19 connected to each of the base members 14 and 17 respectively. The web 21 may be increased or decreased in width for any particular application to provide a greater or lesser sound deadening effect in adjacent rooms. Along one of the upstanding walls such as upstanding Wall 16 aflixed to the base member 14 there is provided a plurality of partially cut-out members 22. The partially cut-out members 22 are adapted to be pushed inwardly so that they protrude over the base member 14 and leave openings as indicated at 23 and 24. The inwardly directed cut-out members then form a tab such as is illustrated at 25 which extends along one side of the studs 11 and 12 to hold them in place Within the supporting channel as illustrated.

A similar supporting channel member is utilized upon the ceiling 10 of the room to maintain the studs in place at the upper terminal ends thereof. The structure is as illustrated in FIG. 1 and is substantially the same as that affixed to the fioor 9 and is so indicated by the utilization of the same reference numerals primed. The supporting channels 13, 13' are held in place upon the floor and ceiling respectively in any manner which is desired but typically by the utilization of a ram-set.

Once the supporting channel members 13, 13' are afiixed in place at themdesired position and the studs 11 and 12 along with the remaining studs (not shown) are inserted in position at the desired intervals, walls 31 and 32 are affixed to the studs by the use of sheet metal screws 33. It should be noted that the partially cut-out members 22 are spaced a predetermined distance apart along the upstanding walls of the supporting channel members 13, 13 in such a manner that workmen when inserting the studs within the supporting channel member can place the studs at any desired position which is equal to or a multiple of the predetermined distance as may be required for the particular structure being constructed. In this manner the studs may be set in place very rapidly by merely inserting the stud and bending the desired cutout members inwardly to support it until the walls are aflixed thereto. It should also be further noted that the partially cut-out members 22 are placed only along the outer facing upstanding Wall of each of the base members 14 and 17 respectively. By so placing the partially cutout members they are readily accessible by a workman and may be bent inwardly with the use of simple hand tools.

By reference to FIG. 2 the particular structure of the stud members and the manner in which they are held in place until the walls are affixed thereto is more readily seen. As is shown in FIG. 2 the stud members are hollow elongated metallic members. The studs fit in place within the supporting channel member 13 and are held by the tabs 41, 4-2 which bend inwardly from the wall 16 to engage the stud 11 and by the tabs 43 and 25 which bend inwardly from the wall 18 to hold the stud 12. The studs 11 and 12 are preferably constructed from approximately 26 gauge sheet metal material that has been formed into a member having a rectangular cross section and thereby providing four flat surfaces. Although a rectangular cross section is illustrated it should be expressly understood that any geometric cross section may be used so long as at least one flat surface is provided and the stud has substantial transverse rigidity to prevent movement of the flat surface during the insertion of screws therein. The ends of the material forming the stud are bent together and crimped as illustrated at 45, thus forming an interconnected four-sided member. Each of the flat surfaces has a plurality of foramen 48 formed therein. The foramina are formed to enable a workman to insert a typical sheet metal screw as is illustrated at 49 through the wall board 31 in such a manner as to cause the point of the sheet metal screw to engage one of the foramina 4-8 which operates as a capture area or trapping center for the point of the sheet metal screw. The trapping center by capturing the screw point thus prevents it from traveling along the surface of the stud while attempting to engage the screw so it can be driven through the surface 46 of the stud to hold the wall board 31 in place. This particular feature is more fully illustrated in FIG. 3, to which reference is hereby made.

As is illustrated in FIG. 3 a surface of a stud 51 has a plurality of foramen 52 formed therein. The foramina 52 may be formed in any manner which is desired but preferably are formed by passing sheet metal stock through rollers having dies adapted to punch the foramina. The major factor to consider is that the foramina 52 form trapping centers for the sheet metal screw points within the surface of the stud member. Since sheet metal screws as opposed to drill point screws are utilized, thus greatly reducing the cost of construction, an important feature of the present invention is that the foramina extend completely through and thereby pierce the wall of the stud.

At the time of the attachment of the wall board as illustrated at 53 to the stud 51 a sheet metal screw 54 is inserted through the wall board and the point thereof contacts the exterior surface of the stud 51. Any sheet metal screw desired may be used and it has been found that a type A sheet metal screw works exceptionally well. After contact with the exterior surface of the stud 51 the point of the screw 54 falls within one of the foramina 52 and is held thereby so that upon turning of the screw by a power screwdriver or such similar tool it will immediately cut into the surface of the stud which defines the particular foramen, and as is typical with sheet metal screws it will form its own threads and pass therethrough thus affixing the wall board 53 securely to the stud 51. As can be seen the foramina 52 are frustum conical in configuration with the major base at the surface to which the building material is to be aflixed and having a length measured along the axis thereof which is greater than the thickness of the sheet metal material from which the stud is made. Such structure provides a relatively large trapping center while at the same time providing a large area into which the threads of the sheet metal screw can cut. This in turn anchors the sheet metal screw firmly thus positively holding the building material in place. For example it has been found that an experienced workman using a 20-ounce claw hammer cannot remove the sheet metal screw from the stud.

Although the metal stud system has been described above with specific reference to the construction of a partition or wall it should be expressly understood that the system may be utilized with a single channel support member as opposed to the double channel support member as illustrated. Alternatively the metal studs may be utilized for furring or for forming a drop ceiling within a particular structure. That is, the metal studs may be supported upon wires aflixed to the ceiling and the ceiling materials attached then directly to the metal studs.

There has thus been disclosed a metal stud system for utilization in constructing non-load bearing walls which system is simple, and easy to install and reduces costs as compared to prior art systems.

What is claimed is:

1. A system for erecting and supporting non-load bearing walls comprising a base provided with a web and flanges extending outwardly from opposite side edges of said web and including bendable cut out members, a sheet metal stud member engaging said base member and removably anchored thereto by said bendable cut out members, said sheet metal stud member including a flange provided with at least one flat surface having a plurality of foramen coextensive therewith to provide a plurality of trapping centers for screw points over said surface of said flange, each said foramen extending completely through said flange and being generally frustum-conical in cross-sectional configuration with the major base thereof being located at the said flat surface against which a wall covering member is adapted to be aflixed, the inside surface of said foramen being relatively smooth and unbroken and having a length measured along the central axis thereof which is greater than the thickness of the sheet metal material from which said stud member is made and a wall covering member affixed to said flat surface of said stud member and a sheet metal screw insertable through said wall covering member and completely through a foramen.

2. A sheet metal structural member for use in a building structure and including a flange provided with at least one flat surface having a plurality of foramen coextensive therewith to provide a plurality of trapping centers for screw points over said entire flat surface of said flange, each of said foramen extending completely through said flange and being generally frustum-conical in cross-sectional configuration with the major base of the foramen being located at the said surface against which a wall covering member is to be affixed, the inside surface of said foramen being relatively smooth and unbroken and each said foramen also having a length measured along the axis thereof which is greater than the thickness of the sheet metal material from which the structural member is made.

(References on following page) ReEei'ences Cited by the Examiner: UNITED STATES PATENTS Hill 52349 Collins 52363 Pomerantz 52348 Berger 52481 Winget 189-36 Balduf 52144 Coddington 52376 X Olson 52364 Spinosa 52242 McGee 52735 FOREIGN PATENTS 134,509 11/1949 Australia.

FRANK L. ABBOTT, Primary Examiner.

HENRY C. SUTI-IERLAND,

RICHARD W. COOKE, 111., Examiners.

J. L. RIDGILL, Assistant Examiner.

10/1962 Nelsson et a1 52-363 

1. A SYSTEM FOR ERECTING AND SUPPORTING NON-LOAD BEARING WALLS COMPRISING A BASE PROVIDED WITH A WEB AND FLANGES EXTENDING OUTWARDLY FROM OPPOSITE SIDES EDGES OF SAID WEB AND INCLUDING BENDABLE CUT OUT MEMBERS, A SHEET METAL STUD MEMBER ENGAGING SAID BASE MEMBER AND REMOVABLY ANCHORED THERETO BY SAID BENDABLE CUT OUT MEMBERS, SAID SHEET METAL STUD MEMBER INCLUDING A FLANGE PROVIDED WITH AT LEAST ONE FLAT SURFACE HAVING A PLURALITY OF FORAMEN COEXTENSIVE THEREWITH TO PROVIDE A PLURALITY OF TRAPPING CENTERS FOR SCREW POINTS OVER SAID SURFACE OF SAID FLANGE, EACH SAID FORAMEN EXTENDING COMPLETELY THROUGH SAID FLANGE AND BEING GENERALLY FRUSTUM-CONICAL IN CROSS-SECTIONAL CONFIGURATION WITH THE MAJOR BASE THEREOF BEING LOCATED AT THE SAID FLAT SURFACE AGAINST WHICH A WALL COVERING MEMBER IS ADAPTED TO BE AFFIXED, THE INSIDE SURFACE OF SAID FORAMEN BEING RELATIVELY SMOOTH AND UNBROKEN AND HAVING A LENGTH MEASURED ALONG THE CENTRAL AXIS THEREOF WHICH IS GREATER THAN THE THICKNESS OF THE SHEET METAL MATERIAL FROM WHICH SAID STUD MEMBER IS MADE AND A WALL COVERING MEMBER AFFIXED TO SAID FLAT SURFACE OF SAID STUD MEMBER AND A SHEET METAL SCREW INSERTABLE THROUGH SAID WALL COVERING MEMBER AND COMPLETELY THROUGH A FORAMEN. 